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Ford Recalls Over 850,000 Vehicles Due to Fuel Pump Defect

Ford Motor Company is recalling more than 850,000 vehicles in the United States due to a defect in the fuel pump that could cause engines to stall unexpectedly while driving. The recall, announced by the National Highway Traffic Safety Administration (NHTSA), is particularly concerning as it increases the risk of accidents, especially in hot weather conditions or when fuel levels are low.

The affected vehicles, manufactured between July 2021 and July 2022, include popular models such as the Ford F-150, Bronco, Explorer, Expedition, Mustang, and several Super Duty pickups. Luxury SUVs like the Lincoln Aviator and Navigator are also included in the recall, impacting a total of 11 different models.

According to the NHTSA, the defect arises from a fuel pump design change made by a supplier in Chihuahua, Mexico, in June 2021. Ford’s internal investigations revealed that issues with internal contamination and tight component spacing in the pump chamber could lead to sudden fuel flow interruptions. This defect can result in drivers experiencing rough idling, misfiring, reduced engine power, or triggering the check engine light prior to stalling.

As of June 2025, Ford has documented 1,860 warranty claims related to this issue. The company is in the process of developing a solution but has not yet announced a specific repair plan. Federal safety officials have also received six consumer complaints regarding vehicles losing power, although no crashes, fires, injuries, or property damage have been reported to date.

Ford estimates that approximately 10 percent of the recalled vehicles may actually have the defect. Dealers were notified of the recall on July 8, and owners can expect to receive interim notification letters between July 14 and July 18. These letters will inform them that their vehicles are part of the recall. Once a repair solution is available, Ford will send out additional notifications, allowing drivers to schedule a free service appointment at their local dealerships.

In the meantime, Ford advises owners to remain vigilant for warning signs and to avoid running their fuel tanks too low, particularly during the summer months when temperatures can exacerbate the defect’s effects.

This recall follows another significant action taken by Ford in July, when the company recalled over 200,000 vehicles due to a glitch affecting backup cameras, which could cause displays to freeze or turn dark, raising further concerns regarding vehicle safety.

As Ford addresses these challenges, the company remains committed to ensuring the safety and reliability of its vehicles. Customers are encouraged to stay informed about the latest developments regarding their vehicles and to seek assistance from their dealerships as needed.

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